Glass composite

ABSTRACT

The invention describes a solid glass composite comprising glass granules and a binder resin which may be used in a wide range of applications, for example, flooring, furniture, lighting, work surfaces and architectural features.

The present invention relates to a glass composite and, in particular,but not exclusively, a glass composite which utilises waste glass fromconsumer, automotive and construction sources.

Research is increasingly being directed to the recycling problems ofwaste glass from various industries and from domestic sources. Recyclingof waste glass for many industries necessitates purification of theglass for its subsequent re-use. Nevertheless, due to the costs ofpurification, much of the waste glass is still committed to undesirablelandfill sites. New applications for the use of waste glass wouldalleviate much of the waste disposal problems associated with wasteglass.

According to a first aspect of the present invention, there is provideda solid glass composite matrix comprising glass granules and a binderresin which has set to bind the granules into a solid composite.

Preferably, the glass granules comprise between 40% and 90% w/w of thecomposite matrix, more preferably, between 65% and 85% w/w of thecomposite matrix, most preferably, between 75% and 85% w/w of thecomposite matrix.

When lower levels of glass granules are utilised other bulking sourcesmay be added to the resin to top up the glass level. For instance, sandmay be added to the mix as a bulking agent and to increase silicalevels. As much as 50% bulking agent may be used, more appropriately asmuch as 30%, most appropriately, as much as 10%. Other potential bulkingagents include mineral fillers such as bauxite and flint. However, theuse of sand or other bulking agents is not preferred.

The percentage level of glass granules achievable in the composite ishigher than is possible with non-resin binders. Typically, the level ofglass granules is higher than 60% w/w of the composite matrix, morepreferably, higher than 70% w/w of the composite matrix, most preferablyhigher than 75% w/w of the composite matrix.

The glass granules may, preferably, comprise up to 75% w/w of thecomposite matrix, more preferably up to 80% w/w of is the compositematrix, most preferably up to 85% w/w of the composite matrix.

Preferably, the glass granules are derived from waste glass. Preferably,the waste glass has been crushed to produce the granules. Typically, thecrushed glass granules have been washed, dried and graded. Typically,the glass granules are obtained from crushed glass which may be derivedfrom glass plate or any other convenient source.

Preferably, the glass granules in the matrix have a grain sizesubstantially between 0.0 mm and 20.0 mm. Preferably, at least 70% ofthe granules are between 0.0 mm and 10.0 mm, more preferably at least80%, most preferably, at least 90% of the granules are between 0.0 mmand 10.0 mm.

Preferably at least 50% w/w of the glass composite matrix comprisesglass granules of grain size 0 mm-6 mm, more preferably, at least 70%w/w of the glass composite matrix comprises glass granules of grain size0 mm-6 mm, most preferably, at least 80% w/w of the glass compositematrix comprises glass granules of grain size between 0 mm-6 mm.

Preferably, at least 10% w/w of the glass composite matrix comprisesglass granules of grain size 0 mm-4 mm, more preferably, at least 20%w/w of the glass composite matrix comprises granules of grain size 0mm-4 mm, most preferably, at least 30% w/w of the glass composite matrixcomprises granules of grain size 0-4 mm.

Preferably, at least 10% w/w of the glass composite matrix comprisesglass granules of grain size, 4 mm-6 mm, more preferably, at least 20%w/w of the glass composite matrix comprises glass granules of grain size4 mm-6 mm, most preferably, at least 30% w/w of the glass compositematrix comprises glass granules of grain size 4-6 mm.

Glass granules of between 6-10 mm may also be present in the compositematrix. Granules between 6-10 mm may be present at a level less than 50%w/w, more preferably, at a level less than 30% w/w, most preferably, ata level less than 25%.

Nevertheless, in some applications it is envisaged that 4-6 mm granulesor 6-10 mm granules are present at up to 90% w/w, more preferably, up to80% w/w, most preferably, up to 70% w/w of the composite matrix.

The waste glass may be derived from any suitable source includingautomotive, construction and consumer sources.

The glass may be clear or coloured or mixtures of colours and the colourof the glass grains may be utilised decoratively. In addition, largerdecorative glass pieces greater than 10 mm grain size may be added tothe composite. In some cases, a decorative outer layer containing suchpieces may be added to the base matrix. Such pieces larger than 10 mmhave not been taken into account herein in relation to the total weightof composite in stating the preferred % w/w of glass grains in thecomposite or the preferred % w/w of resin or other components in thecomposite.

Preferably, the matrix is ground after setting to provide a finish.Polishing may also be carried out. However, advantageously, withcompositions of the invention, it is also envisaged that no grinding orsecondary processes will be required. For instance, when producing tilesfrom moulds, it is possible to produce tiles from the moulds with highquality finish.

Preferably, the binder resin comprises between 5% w/w and 20% w/w of thecomposite matrix, more preferably between 7.5% and 17.5% of thecomposite matrix, most preferably, between 10% and 15% w/w of thecomposite matrix.

Preferably, the resin is polymeric and requires a curing agent orinitiator to set.

Preferably, a coupling agent is present in the composite, to couple theglass and resin components together during setting of the composite,preferably, by chemical reaction with both components.

The coupling agent may be a silane coupling agent, preferably, anorgano-functional silane coupling agent.

Preferably, the coupling agent is selected from a suitable silane,titanate ester or zirco-aluminate.

The resin may be selected from any suitable binder resin including epoxyresins, polyurethane binders, unsaturated polyester binders and polyC₁-C₂ alkyl methacrylate binders. Preferably, the polyalkyl methacrylatebinder is polymethyl methacrylate.

A typical epoxy resin binder consists of the diglycidyl ether ofbisphenol F or bisphenol A or mixtures thereof. Typically, the averagenumber molecular weight is less than or equal to 1000, more preferably800, most preferably, 700. A reactive diluent may be added to suitviscosity requirements. Typically, the reactive diluents comprisemono-functional or di-functional aliphatic or cycloaliphatic glycidylethers or esters. One or more of these may be mixed together in anyproportions or used solely. A preferred diluent is a less viscousglycidyl ether such as C₁₂-C₁₄ alkyl glycidyl ether. The specificdiluent may be varied to suit viscosity requirements. Typically, thediluent is present at a level of 5-30% of the pre-cured resin, morepreferably 10-25%.

The coupling agent may be present in the pre-cured resin at a level of0.1-4.0% W/w, more preferably 0.5-3.0%, most preferably 1.0-2.0% w/w.

The curing agent is preferably a UV stable moiety. A suitable UV stablecuring agent for epoxy resin isoctahydro-4,7-methano-1H-indendinethylamine.

Typical polyurethane binders comprise polyethers and/or polyesterpolyols together with aliphatic isocyanate curing agents.

Typical unsaturated polyester binders may comprise light stabilisedorthophthalic or isophthalic resins together with a suitable initiatorsuch as an organic peroxide. Typically, the alkyl methacrylate bindersconsist of aliphatic polyalkyl methacrylate copolymers or terpolymerstogether with a suitable initiator such as an organic peroxideinitiator.

Preferably, the binder resin is UV stable. Preferably the ratio of glassgranules to binder resin and coupling agent is in the range of 6:1 to3:1, more preferably 11:2 to 7:2, most preferably 5:1 to 4:1.

According to a second aspect of the present invention, there is provideda method of producing a glass composite comprising the steps of:—

-   contacting an aggregate of glass granules of average grain size less    than 10 mm with a binder resin,-   mixing the granules into the un-set resin,-   and allowing the resin to set so that the resin sets the granules    into a solid composite matrix.

Preferably, the method of the second aspect may incorporate any one ormore of the features of the first aspect of the invention.

Advantages of the use of resin together with waste glass granulesinclude the low level of chemical reactivity between the resin and thesilica in the glass so that the composite produced is highly stable.Furthermore, it has been found that it is possible to introduce higherlevels of glass in a resin substrate than alternative substrates. Due tocontamination risks, preferably, the resin is substantially solventfree.

The composite of the invention provides an impervious surface which maybe UV stable and has excellent chemical resistance against typicalmaterials such as:

-   oil, petrol, diesel, anti-freeze, salts, beverages, urine and dilute    acids and alkalis.

Advantageously, prior to setting, the composite may be shaped in threedimensions and inconsistencies in the final set shape may be simplycorrected by filling or polishing as is necessary. The castingtechniques may be any of those known to those skilled in the artincluding vacuum-, pressure- and vibro-casting.

The composites of the invention may be utilised in many applicationsincluding:

-   internal and external flooring, furniture, lighting, work surfaces,    architectural features such as skirting, architraves and sanitary    work and the invention extends to methods of making such products    using the method of the second aspect of the invention or the    product of the first aspect. Furthermore, impervious examples of the    product may be utilised as material for commercial food preparation    surfaces and chemical, including pharmaceutical, preparation    surfaces. It is also envisaged that the invention may be used in    applications which require high resistance to radiation such as    natural, electro magnetic or nuclear radiation. Such applications    include products and fittings in x-ray facilities in hospitals and    sites within the nuclear industry. For such applications, it is    preferred that the lead and/or barium level in the glass granules is    sufficient to appreciably reduce the radiation transmission through    the composite. A possible source of such glass granules with a high    level of lead and/or barium is waste glass from VDU screens.

Preferably, the glass granules for screening applications has lead orbarium or combined lead/barium levels at at least 3% by weight as apercentage of the raw constituent of the glass, more preferably at least7% by weight, most preferably, at least 10% by weight. Preferably, thelead or barium levels or combined lead/barium levels for suchapplications are in the range 10-70% by weight in the glass granules,more preferably 20-70% by weight in the glass granules, most preferably,40-70% by weight in the glass granules.

Further advantages of the composites of the invention are the highflexural strength and impact resistance. It is envisaged that theseproperties may be utilised in the production of body armour, includingstab and ballistic body armour, either as part of a laminate withavailable materials or for total replacement of existing materials.

Tests have shown that materials according to the invention haveexcellent slip resistance, impact resistance, low thermal expansion,high compressive strength, high flexural strength, high tensile strengthand high abrasion resistance.

Internal and external flooring may be in the form of floor tiles.Preferably, the floor tiles are at least 3 mm, more preferably at least6 mm. A preferred range is 4-35 mm, a more preferred range 6-25 mm, amost preferred range is 8-20 mm. Such thickness ranges are considerablyless than those employed for the equivalent concrete paving which theyreplace. Advantageously, the toughness and flexibility of the materialallows much thinner floor coverings to be used whereas concrete ofequivalent thickness would crack due to its higher brittlenessthreshold.

Examples of the present invention will now be described.

EXAMPLES

The compositions of examples 1-10 are shown respectively in tables 1-5and 16-20 which show the relative weight percentages and absoluteweights of the various constituents of the composites.

The epoxy resin in examples 1-10 comprises a blend of 80-84% bisphenol A& F, 15-19% C₁₂-C₁₄ alkyl glycidyl ether as a diluent and 1%glycidoxy-functional silane coupling agent.

All these products produced high quality products after grinding andpolishing.

The method of preparation of composite is as follows.

-   i. The glass is weighed out in the correct percentages of each grain    size and colour. (Usually 0-4 mm, 4-6 mm and 6-10 mm, in colours    green bottle, amber bottle, blue bottle and clear plate). See    examples.-   ii. The resin binder is mixed to the correct ratios (Base, catalyst    and pigment), see examples, until an even dispersion is achieved.-   iii. The glass is then mixed thoroughly into the mixed resin binder.-   iv. The “mix” is then either trowelled into moulds (for production    of tiles or three dimensional items eg. furniture) or laid directly    onto a preprepared floor surface as a screed.    -   Curing times@20° C.    -   24 hours . . . 70%    -   7 days . . . 95%    -   28 days . . . 100%    -   Although all curing times can be varied by using additives.-   v. Ideally, the mix should be “finished” in the period after 24h and    before 48h, to the finish required (Currently, ground, polished or    wire brushed)

TABLE 1 (Example 1) Constituency Percentage Weight Comments Epoxy resin12.61 378.34 Clear Octahydro- 6.42 192.60 Clear 4,7-methano- 1H-indendimethyl amine. Pigment 0.03 0.94 RAL No. 4004 BS No. Aggregate mm39.97 1200 Clear Plate 0.4 Aggregate mm 40.97 1230 Clear Plate 4-6Aggregate mm 0 0 6-10 Total 100 3001.88

TABLE 2 (Example 2) Constituency Percentage Weight Comments Epoxy resin11.67 262.92 Clear Octahydro- 5.89 132.75 Clear 4,7-methano- 1H-indendimethyl amine. Pigment 0.12 2.60 RAL No. 6019 Bs No. Aggregate mm40.87 920.50 Clear Plate 0.4 Aggregate mm 41.45 933.75 Clear Plate 4-6Aggregate mm 0 0 6-10 Total 100 2252.52

TABLE 3 (Example 3) Constituency Percentage Weight Comments Epoxy resin13.11 996.87 Clear Octahydro- 6.35 483 Clear 4,7-methano- 1H-indendimethyl amine. Pigment 0.13 9.87 RAL No. 9003 BS No. Aggregate mm35.31 2685.00 Clear Plate 0-4 Aggregate mm 45.10 3430.00 Clear Plate 4-6Aggregate mm 0 0 6-10 Total 100 7604.74

TABLE 4(a) (Example 4a) Constituency Percentage Weight Comments Epoxyresin 10.95 93.68 Clear Octahydro- 5.27 45.05 Clear 4,7-methano- 1H-indendimethyl amine. Pigment 0.32 2.73 RAL No. 9003 Aggregates 0.4 mm58.13 497.25 Blue 4-6 mm 25.34 216.75 Blue 6-10 mm 0.00 0.00 Total 100855.46

TABLE 4(b) (Example 4b) Octahydro- 4,7-methano- 1H- indendimethyl amine.RAL No. 9003 0.4 mm 4-6 mm 1.98 30.00 Green 6-10 mm Blue Easy to trowel

TABLE 5 Constituency Percentage Weight Comments Epoxy resin 14.04 120.15Clear Octahydro- 6.85 58.65 Clear 4,7-methano- 1H- indendimethyl amine.Pigment RAL No. 9003 0.04 0.30 5005 0.01 0.10 BS No. Aggregates 0-4 mm19.87 170.00 Clear Plate 4-6 mm 38.74 331.50 Clear plate 0.58 5.00 Green6-10 mm 19.87 170.00 Total 100.00 855.70

Tables 6-10 reveal grain size distribution for suitable glass granularsamples which may be used with resins in accordance with the presentinvention.

TABLE 6 Breakdown of Glass Samples Grain Size (mm) Mass (g) Percentage  2-3.15 293.30 29.33   1-2 400.30 40.03 0.71-1 97.10 9.71  0.5-0.7162.90 6.29 0.25-0.5 76.50 7.65   0-0.25 69.90 6.99

TABLE 7 Grain Size (mm) Mass (g) Percentage 3.15-4 5.00 0.50   2-3.15244.70 24.47   1-2 338.50 33.85 0.71-1 102.00 10.20  0.5-0.71 79.20 7.920.25-0.5 109.50 10.95   0-0.25 121.10 12.11

TABLE 8 Grain Size (mm) Mass (g) Percentage    >4 78.60 7.86 3.15-4127.00 12.70   2-3.15 239.00 23.90   1-2 244.00 24.40 0.71-1 114.5011.45  0.5-0.71 75.10 7.51 0.25-0.5 91.30 9.13   0-0.25 30.50 3.05

TABLE 9 Grain size (mm) Mass (g) Percentage    >4 134.03 13.40 3.15-4192.06 19.21   2-3.15 339.50 33.95   1-2 174.20 17.42 0.71-1 52.58 5.26 0.5-0.71 31.28 3.13 0.25-0.5 44.60 4.46   0-0.25 31.75 3.17

TABLE 10 Grain Size (mm) Mass (g) Percentage >4 112.00 11.20 3.15-4172.00 17.20   2-3.15 315.55 31.56   1-2 200.00 20.00 0.71-1 77.00 7.70 0.5-0.71 46.00 4.60 0.25-0.5 49.50 4.95   0-0.25 28.00 2.80

Test examples 6-10 have compositions as set out in tables 16-20.

The test results on example 6-10 are shown in tables 11-15 respectively.

Table 11 shows the impact resistance of example 6 which has been carriedout in four separate tests. The recorded penetration is very low giventhat a maximum indentation depth of 3 mm is all that is required for ahigh (category A) soundness level. Table 12 shows that the coefficientof expansion of example 7 is similar to steel which makes the materialhighly suitable for applications in combination with steel to minimisedifferential rates of expansion and contraction in variable temperatureenvironments.

TABLE 11 Recorded Penetration Test No 1 0.5 mm Test No 2 0.4 mm Test No3 0.2 mm Test No 4 0.0 mm

TABLE 12 Mean Coefficient of Test age 7 days 3.0 × 10⁻⁵ Test age 28 days4.2 × 10⁻⁵

Table 13 shows that the flexural strength of example 8 is very high andthis may give opportunities in combination with flexible backingsurfaces or substrates such as soil or earth.

TABLE 13 Flexural Strength (N/mm²) Test age 7 days    (See Note 1) Testage 28 days 41.9 (see Note 2)

-   Note 1—Test pieces flexed without failure, flexural strength can not    be recorded.-   Note 2—Test pieces 1 and 3 had air bubbles on the fracture surface,    test 2 flexed a long way before failure.

Table 14 shows a comparison of abrasion resistance with a concrete floorslab for example 9. The sample performs at a much higher level and showsimproved abrasion resistance compared with concrete.

TABLE 14 Results from an external concrete floor slab (For Mean WearDepth comparison) Test Duration 2 hours 0.038 mm Test Duration 1 hour0.025 mm Test Duration  0.00 mm 1.21 mm 15 minutes

Advanced humidity and resistance to liquids tests for example 1 werecarried out. The resistance to humidity test comprised cycliccondensation between −10° C. and 40° C. following BS 3900 Part F2: 1989.The resistance to liquids test was carried out using the water immersionmethod of BS 3900: Part G8: 1993. The example was found to havesatisfactory resistance to water immersion and cyclic condensation attemperatures between −10° C. and 40° C. at 100% humidity.

TABLE 15 (Example 6) Impact Testing (Sample) Constituency PercentageWeight Comments Epoxy resin 11.17 251.67 Clear Octahydro- 5.65 127.35Clear 4,7-methano- 1H- indendimethyl amine. Pigment 0.06 1.25 RAL No.2010 BS No. Aggregates 0-4 mm 42.66 960.97 Clear Plate 4-6 mm 40.46911.25 Clear Plate 6-10 mm 0.00 0.00 TOTAL 100.00 2252.49

TABLE 16 (Example 7) Coefficient of Thermal Expansion SampleConstituency Percentage Weight Comments Epoxy resin 13.22 396.99 ClearOctahydro- 5.80 174.00 Clear 4,7-methano- 1H- indendimethyl amine.Pigment 0.03 0.99 RAL No. 1014 Aggregates 20.49 615.00 Green 0-4 mm615.00 Amber 4-6 mm 19.99 600.00 Amber 19.99 600.00 Green Aggregate mm 00 6-10 TOTAL 79.51 3001.98

TABLE 17 (Example 8) Flexural Strength Sample Constituency PercentageWeight Comments Epoxy resin 11.17 251.67 Clear Octahydro- 5.65 127.35Clear 4,7-methano- 1H- indendimethyl amine. Pigment 0.06 1.25 RAL No.2010 Aggregates 0-4 mm 42.66 960.97 Clear Plate 4-6 mm 40.46 911.25Clear Plate 6-10 mm 0.00 0.00 TOTAL 100.00 2252.49

TABLE 18 (Example 9) Abrasion Testing Sample Constituency PercentageWeight Comments Epoxy resin n 13.25 397.98 Clear Octahydro- 5.79 174.00Clear 4,7-methano- 1H- indendimethyl amine. Pigment 0.07 1.98 RAL No.9003 Aggregates 0-4 mm 47.94 1440.00 Green 4-6 mm 32.95 990.00 Green6-10 mm 0.00 0.00 TOTAL 100.00 3003.96

TABLE 19 (Example 10) Coefficient of Friction Sample ConstituencyPercentage Weight Comments Epoxy resin 11.17 251.67 Clear Octahydro-5.65 127.35 Clear 4,7-methano- 1H- indendimethyl amine. Pigment 0.061.25 RAL 2010 Aggregates 0-4 mm 42.66 960.97 Clear Plate 4-6 mm 40.46911.25 Clear Plate 6-10 mm 0 0 TOTAL 100.00 2252.49

The reader's attention is directed to all papers and documents which arefiled concurrently with or previous to this specification in connectionwith this application and which are open to public inspection with thisspecification, and the contents of all such papers and documents areincorporated herein by reference.

All of the features disclosed in this specification (including anyaccompanying claims, abstract and drawings), and/or all of the steps ofany method or process so disclosed, may be combined in any combination,except combinations where at least some of such features and/or stepsare mutually exclusive.

Each feature disclosed in this specification (including any accompanyingclaims, abstract and drawings), may be replaced by alternative featuresserving the same, equivalent or similar purpose, unless expressly statedotherwise. Thus, unless expressly stated otherwise, each featuredisclosed is one example only of a generic series of equivalent orsimilar features.

The invention is not restricted to the details of the foregoingembodiment(s). The invention extend to any novel one, or any novelcombination, of the features disclosed in this specification (includingany accompanying claims, abstract and drawings), or to any novel one, orany novel combination, of the steps of any method or process sodisclosed.

1. A solid glass composite matrix comprising glass granules and a binderresin which has been cured and which binds the glass granules into asolid composite, wherein the solid glass composite matrix comprises morethan 60% w/w of glass granules which have a grain size of 4 mm-6 mm. 2.A solid glass composite matrix, comprising glass granules and a binderresin which has been cured and which binds the glass granules into asolid composite, wherein the solid glass composite matrix comprises morethan 60% w/w of glass granule which have a grain size of 4 mm-6 mm andwhich further comprises bulking sources selected from the groupconsisting of sand, silica, bauxite and flint.
 3. A solid glasscomposite matrix according to claim 1, wherein the glass granules arederived from waste glass.
 4. A solid glass composite matrix, comprisingglass granules and a binder resin which has been cured and which bindsthe glass granules into a solid composite, wherein the solid glasscomposite matrix comprises more than 60% w/w of glass granules grainsize of 4 mm-6 mm and which further comprises glass granules in thematrix which have a grain size substantially between 0.0 mm and 20.0 mm.5. A solid glass composite matrix according to claim 1, wherein at least50% w/w of the glass composite matrix further comprises glass granulesof grain size between 0 mm-6 mm.
 6. A solid glass composite matrixaccording to claim 1, wherein at least 10% w/w of the glass compositematrix comprises glass granules of grain size between 0 mm-4 mm.
 7. Asolid glass composite matrix according to claim 1, wherein the binderresin comprises between 5% w/w and 20% w/w of the composite matrix.
 8. Asolid glass composite matrix, comprising glass granules and a binderresin which has been cured and which binds the glass granules into asolid composite, wherein the solid glass composite matrix comprises morethan 60% w/w of glass granules a grain size of 4 mm-6 mm and wherein acoupling agent is present in the composite, to couple the glass andresin components together during setting of the composite.
 9. A solidglass composite matrix, comprising glass granules and a binder resinwhich has been cured and which binds the glass granules into a solidcomposite, wherein the solid glass composite matrix comprises more than60% w/w of glass granules a grain size of 4 mm-6 mm and wherein areactive diluent is added to suit viscosity requirements.
 10. A solidglass composite matrix according to claim 9, wherein the diluent ispresent at a level of 5-30% of the pre-cured resin.
 11. A solid glasscomposite matrix according to claim 8, wherein the coupling agent ispresent in the pre-cured resin at a level of 0.1-4.0% w/w.
 12. A solidglass composite matrix according to claim 8, wherein the ratio of glassgranules to binder resin and coupling agent is in the range of 6:1 to3:1.
 13. A solid glass composite matrix according to claim 1, whereinthe glass granules for screening applications have lead or barium orcombined lead/barium levels of at least 3% by weight.
 14. A solid glasscomposite matrix according to claim 13, wherein the lead or bariumlevels or combined lead/barium levels for such applications are in therange 10-70% by weight in the glass granules.
 15. The solid glasscomposite matrix of claim 1 wherein the glass granules comprise between65% and 85% w/w of the composite matrix.
 16. The solid glass compositematrix of claim 1 which has a ratio of glass granules to binder resinand a coupling agent which is in the range of 6:1 to 3:1.
 17. The solidglass composite matrix of claim 1 wherein the binder resin is a curedresin selected from the group consisting of epoxy resins, polyurethanebinders, unsaturated polyesters and poly C₁-C₂ alkyl methacrylatebinders.
 18. The solid glass composite matrix of claim 1 which has abinder resin which is an epoxy resin.
 19. A method of producing a glasscomposite comprising the steps of: contacting an aggregate of glassgranules of average grain size between 0 mm and less than 10 mm with abinder resin, mixing the granules into the un-set resin, and allowingthe resin to set so that the resin sets the granules into a solidcomposite matrix wherein the solid glass composite matrix comprises morethan 60% w/w of glass granules which have a grain size of 4 mm-6 mm. 20.The method of claim 19 where the binder resin is admixed with a couplingagent which is effective to couple the glass and resin componentstogether by chemical reaction.
 21. A solid glass composite matrixcomprising glass granules and a binder resin which has been cured, andbinds the glass granules into a solid composite, wherein said binderresin further comprises a reactive diluent which is added to controlviscosity; and wherein the reactive diluent is selected from the groupconsisting of mono-functional 1 aliphatic glycidyl ethers, di-functional1 aliphatic glycidyl ethers, mono-functional cycloaliphatic ethers,di-functional cycloaliphatic glycidyl ethers, mono-functional 1aliphatic glycidyl esters, di-functional 1 aliphatic glycidyl esters,mono-functional cycloaliphatic glycidyl esters, and di-functionalcycloaliphatic glycidyl esters.